U.S. patent application number 17/059009 was filed with the patent office on 2021-07-08 for glass panel unit manufacturing method.
The applicant listed for this patent is PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD.. Invention is credited to Hiroyuki ABE, Kazuya HASEGAWA, Tasuku ISHIBASHI, Haruhiko ISHIKAWA, Masataka NONAKA, Takeshi SHIMIZU, Eiichi URIU.
Application Number | 20210207427 17/059009 |
Document ID | / |
Family ID | 1000005521113 |
Filed Date | 2021-07-08 |
United States Patent
Application |
20210207427 |
Kind Code |
A1 |
SHIMIZU; Takeshi ; et
al. |
July 8, 2021 |
GLASS PANEL UNIT MANUFACTURING METHOD
Abstract
A glass panel unit manufacturing method includes a bonding step,
an insertion step, an evacuation step, and a sealing step. The
bonding step includes bonding a first substrate having an
evacuation port and a second substrate together with a bonding
material provided between the first substrate and the second
substrate and having a frame shape to form an internal space. The
insertion step includes inserting a sealing material into the
evacuation port. The evacuation step includes evacuating the
internal space through the exhaust passage. The sealing step
includes deforming the sealing material by heating while an
evacuated state in the internal space is maintained. In a state
where the sealing material blocks ventilation between the
evacuation port and the internal space, gas is supplied through the
exhaust passage toward the evacuation port.
Inventors: |
SHIMIZU; Takeshi; (Osaka,
JP) ; NONAKA; Masataka; (Osaka, JP) ;
ISHIKAWA; Haruhiko; (Osaka, JP) ; URIU; Eiichi;
(Osaka, JP) ; HASEGAWA; Kazuya; (Osaka, JP)
; ISHIBASHI; Tasuku; (Ishikawa, JP) ; ABE;
Hiroyuki; (Osaka, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO., LTD. |
Osaka |
|
JP |
|
|
Family ID: |
1000005521113 |
Appl. No.: |
17/059009 |
Filed: |
April 15, 2019 |
PCT Filed: |
April 15, 2019 |
PCT NO: |
PCT/JP2019/016173 |
371 Date: |
November 25, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E06B 3/677 20130101;
C03C 27/06 20130101; E06B 3/6736 20130101; E06B 3/6612
20130101 |
International
Class: |
E06B 3/677 20060101
E06B003/677; C03C 27/06 20060101 C03C027/06; E06B 3/66 20060101
E06B003/66 |
Foreign Application Data
Date |
Code |
Application Number |
May 30, 2018 |
JP |
2018-104076 |
Claims
1. A glass panel unit manufacturing method, comprising: a bonding
step of bonding a first substrate and a second substrate together
with a bonding material provided between the first substrate and
the second substrate and having a frame shape to form an internal
space, the first substrate including a glass panel and having an
evacuation port, the second substrate including a glass panel, the
internal space being surrounded by the bonding material between the
first substrate and the second substrate; an insertion step of
inserting a sealing material into the evacuation port of the first
substrate; an evacuation step of evacuating the internal space
through an exhaust passage by detachably connecting the exhaust
passage to the evacuation port; and a sealing step of: deforming
the sealing material by heating; and sealing the evacuation port
with the sealing material deformed by being heated while an
evacuated state in the internal space is maintained, the sealing
step including supplying gas through the exhaust passage toward the
evacuation port in a state where the sealing material softened by
being heated blocks ventilation between the evacuation port and the
internal space.
2. The glass panel unit manufacturing method of claim 1, wherein
the gas is heated external air.
3. The glass panel unit manufacturing method of claim 1, wherein
the gas is compressed air.
4. The glass panel unit manufacturing method of claim 1, wherein
the gas has a temperature in a range of 100.degree. C. to
300.degree. C.
5. The glass panel unit manufacturing method of claim 1, wherein
the gas has a temperature in a range of 200.degree. C. to
300.degree. C.
6. The glass panel unit manufacturing method of claim 1, wherein
the gas has a temperature in a range of +/-100.degree. C. from a
softening point of the sealing material.
7. The glass panel unit manufacturing method of claim 1, wherein
the gas has a temperature in a range of +/-50.degree. C. from a
softening point of the sealing material.
8. The glass panel unit manufacturing method of claim 1, wherein
the evacuation step and the sealing step are performed with an
exhaust device having the exhaust passage and a sealing head
connected to the exhaust passage in a state where the sealing head
is attached to the first substrate, and the sealing step includes
supplying gas through the exhaust passage and the sealing head
toward the evacuation port.
9. The glass panel unit manufacturing method of claim 8, in the
evacuation step and the sealing step, a plurality of the sealing
heads are used.
10. The glass panel unit manufacturing method of claim 3, wherein
the evacuation step and the sealing step are performed with an
exhaust device having the exhaust passage and a compressor
connected to the exhaust passage and a sealing head connected to
the exhaust passage in a state where the sealing head is attached
to the first substrate, and the sealing step includes suppling
compressed gas from the compressor through the exhaust passage and
the sealing head toward the evacuation port.
11. The glass panel unit manufacturing method of claim 10, wherein
in the evacuation step and the sealing step, a plurality of the
sealing heads are used
12. A glass panel unit manufacturing method of claim 1, wherein in
the sealing step, the sealing material softened by being heated is
deformed by being pressed by the pressing member inserted into the
evacuation port, and the sealing material deformed by being pressed
blocks ventilation between the evacuation port and the internal
space.
13. The glass panel unit manufacturing method of claim 1, wherein
the sealing step includes irradiating the sealing material with
infrared rays through the second substrate to locally heat the
sealing material.
Description
TECHNICAL FIELD
[0001] The present disclosure relates to a glass panel unit
manufacturing method.
BACKGROUND ART
[0002] A thermally insulating glass panel unit is obtained by
reducing the pressure in an internal space formed between a pair of
substrates arranged to face each other and hermetically sealing the
internal space while maintaining the reduced pressure there.
[0003] Patent Literature 1 discloses a technique according to which
an exhaust pipe made of glass is connected to an evacuation port
formed in one of a pair of substrates, the pressure in an internal
space is reduced through the exhaust pipe, and then the exhaust
pipe is melted by heat and is cut off.
[0004] The known technique of the background art leaves a trace of
the exhaust pipe thus cut off on an outer surface of a glass panel
unit thus formed.
CITATION LIST
Patent Literature
[0005] Patent Literature 1: JP 2001-354456 A
SUMMARY OF INVENTION
[0006] It is an object of the present disclosure to provide a glass
panel unit having evacuated internal space, such that no trace of
an exhaust pipe is left thereon.
[0007] A glass panel unit manufacturing method according to one
aspect of the present disclosure includes a bonding step, an
insertion step, an evacuation step, and a sealing step. The bonding
step is a step of bonding a first substrate and a second substrate
together with a bonding material provided between the first
substrate and the second substrate and having a frame shape to form
an internal space. The first substrate includes a glass panel and
has an evacuation port. The second substrate includes a glass
panel. The internal space is surrounded by the bonding material
between the first substrate and the second substrate. The insertion
step is a step of inserting a sealing material into the evacuation
port of the first substrate. The evacuation step is a step of
evacuating the internal space through an exhaust passage by
detachably connecting the exhaust passage to the evacuation port.
The sealing step is a step of: deforming the sealing material by
heating; and sealing the evacuation port with the sealing material
deformed by being heated while an evacuated state in the internal
space is maintained. The sealing step includes supplying gas
through the exhaust passage toward the evacuation port in a state
where the sealing material softened by being heated blocks
ventilation between the evacuation port and the internal space.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIG. 1 is a perspective view illustrating a bonding step of
a glass panel unit manufacturing method of one embodiment;
[0009] FIG. 2 is a plan view illustrating a work in progress formed
by the bonding step;
[0010] FIG. 3 is a sectional view along line A-A of FIG. 2;
[0011] FIG. 4 is a plan view illustrating an evacuation step of the
manufacturing method;
[0012] FIG. 5 is a sectional view taken along line B-B of FIG.
4;
[0013] FIG. 6 is a sectional view illustrating one state in a
sealing step of the manufacturing method;
[0014] FIG. 7 is a sectional view illustrating a next state of the
one state of the sealing step;
[0015] FIG. 8 is a schematic diagram illustrating an exhaust device
used in the manufacturing method;
[0016] FIG. 9 is a perspective view illustrating a glass panel unit
obtained by the manufacturing method;
[0017] FIG. 10 is a view schematically illustrating an exhaust
device used in a first variation of the manufacturing method;
[0018] FIG. 11 is a view schematically illustrating an exhaust
device used in a second variation of the manufacturing method;
and
[0019] FIG. 12 is a view schematically illustrating an exhaust
device used in a third variation of the manufacturing method.
DESCRIPTION OF EMBODIMENTS
Embodiment
[0020] A glass panel unit manufacturing method of one embodiment
(hereinafter simply referred to as a "manufacturing method of one
embodiment") will be described).
[0021] The manufacturing method of the one embodiment is a method
for manufacturing a glass panel unit 9 and includes a bonding step,
an insertion step, an evacuation step, and a sealing step.
[0022] In the manufacturing method of the one embodiment, the
bonding step is first performed to form a work in progress 8. The
work in progress 8 is an intermediate product obtained while the
glass panel unit 9 is manufactured. In the insertion step performed
after the bonding step, a sealing material 89 is inserted into an
evacuation port 815 of the work in progress 8 thus formed. In the
evacuation step and the sealing step performed after the insertion
step, an internal space 85 is evacuated and sealed with an exhaust
device 1 and a sealing head 7 shown in FIG. 8, thereby
manufacturing the glass panel unit 9 having high thermal insulation
properties. Each of the steps will be described in detail
below.
[0023] First of all, the bonding step will be described. As
illustrated in FIG. 1 and the like, the bonding step includes
disposing a first substrate 81, a second substrate 82, a bonding
material 83, a plurality of pillars 84, and a dam 87 at respective
prescribed locations. Specifically, the bonding material 83, the
dam 87, and the plurality of pillars 84 are disposed on one surface
of the second substrate 82 (in other words, an upper surface of the
second substrate 82). The first substrate 81 is located above and
faces the second substrate 82.
[0024] The first substrate 81 includes a glass panel 810 which is
light transmissive. The second substrate 82 includes a glass panel
820 which is light transmissive. In the following description, the
glass panel 810 included in the first substrate 81 is referred to
as a first glass panel 810, and the glass panel 820 included in the
second substrate 82 is referred to as a second glass panel 820.
[0025] Examples of materials for the first glass panel 810 and the
second glass panel 820 include, but not limited to, soda-lime
glass, high strain-point glass, chemically strengthened glass,
no-alkali glass, quartz glass, Neoceram, and thermally strengthened
glass.
[0026] As illustrated in FIG. 3, a low-emissivity film 812 is
bonded to one surface of the first glass panel 810 (in other words,
a lower surface of the first glass panel 810). The first substrate
81 has a surface which faces the second substrate 82 and most of
which is a surface of the low-emissivity film 812. The
low-emissivity film 812 is a film containing metal, such as silver,
with low emissivity and has the capability of reducing the transfer
of heat due to radiation. The second substrate 82 has a surface
which faces the first substrate 81 and which is a surface of the
second glass panel 820.
[0027] For the first substrate 81, the low-emissivity film 812 is
not essential, and the first substrate 81 does not have to include
the low-emissivity film 812. The first substrate 81 may include, in
place of the low-emissivity film 812, a film having a function
different from the low-emissivity film 812. Similarly, the second
substrate 82 may include the low-emissivity film or may include a
film having a function different from the low-emissivity film.
[0028] The first substrate 81 has the evacuation port 815. The
evacuation port 815 penetrates the first substrate 81 in a
thickness direction of the first substrate 81. The evacuation port
815 penetrates the first glass panel 810 in a thickness direction
of the first glass panel 810.
[0029] The bonding material 83 is disposed on the second substrate
82 (i.e., the second glass panel 820) by an application apparatus
such as a dispenser. As illustrated in FIG. 1, the bonding material
83 is disposed to have a frame shape along an outer peripheral edge
of the one surface of the second substrate 82 (in other words, the
upper surface of the second substrate 82).
[0030] The dam 87 is disposed on the second substrate 82 (i.e., the
second glass panel 820) by an application apparatus such as a
dispenser in the same manner. The dam 87 is a portion for
restricting a deformation range of the sealing material 89.
[0031] The dam 87 is disposed at a prescribed location on the one
surface of the second substrate 82 (in other words, the upper
surface of the second substrate 82). The bonding material 83 and
the dam 87 are preferably made of the same material (e.g., glass
frit) but may be made of different materials. The shape of the dam
87 is an annular shape having a cut-off 875 and is more
specifically C-shaped, but the shape of the dam 87 is not limited
to this example.
[0032] The plurality of pillars 84 are arranged in a regular
pattern within an area which is part of the one surface of the
second substrate 82 and which is surrounded by the bonding material
83. The dimensional shape, the number, and the pattern of the
plurality of pillars 84 are not particularly limited. The plurality
of pillars 84 are preferably made of a resin, but this should not
be construed as limiting. The plurality of pillars 84 may be made
of, for example, metal.
[0033] In the bonding step, the first substrate 81 and the second
substrate 82 disposed to face each other as described above are
hermetically bonded together via the bonding material 83.
[0034] Specifically, the first substrate 81 and the second
substrate 82 between which the bonding material 83, the dam 87, and
the plurality of pillars 84 are sandwiched are heated in a bonding
furnace such as a circulating hot air oven, the bonding material 83
is once softened by heat, and then, the bonding material 83 is
cured as the temperature lowers.
[0035] The internal space 85 is formed between the first substrate
81 and the second substrate 82 through the bonding step (see, for
example, FIG. 3). The internal space 85 is surrounded by the first
substrate 81, the second substrate 82, and the bonding material 83
and is communicated with the outside space through only the
evacuation port 815.
[0036] As illustrated in FIG. 2, the evacuation port 815 of the
first substrate 81 is surrounded by the dam 87 when viewed in a
direction in which the first substrate 81 and the second substrate
82 face each other. In the manufacturing method of the one
embodiment, the dam 87 has the one cut-off 875, but the dam 87 may
have a plurality of cut-offs 875.
[0037] Next, the insertion step will be described. The insertion
step is a step prior to the evacuation step and the sealing step
and includes inserting the sealing material 89 and a plate 88 in
this order into the evacuation port 815 of the work in progress 8.
The sealing material 89 is, for example, a solid sealing material
formed from glass frit. The plate 88 is a disk-shaped plate made
of, for example, metal.
[0038] Each of the sealing material 89 and the plate 88 has an
outer shape smaller than the outer shape of the evacuation port
815. The sealing material 89 is sandwiched between the plate 88
inserted in the evacuation port 815 and the second substrate
82.
[0039] Next, the evacuation step will be described. The evacuation
step is executed by the exhaust device 1 and the sealing head 7
connected thereto. The sealing head 7 is detachably attached to a
corner portion 8a of the work in progress 8.
[0040] As illustrated in FIG. 5 and the like, the sealing head 7
includes an tubular section 75 for exhaustion, a first frame 71
supporting the tubular section 75, a heater 79, a second frame 72
supporting the heater 79, and the spring mechanism 73. The spring
mechanism 73 is configured to apply biasing force to the first
frame 71 and the second frame 72 in a direction in which the first
frame 71 and the second frame 72 come close to each other. The
first frame 71 and the second frame 72 are coupled to each other to
be relatively displaceable in a direction in which the first
substrate 81 and the second substrate 82 face each other.
[0041] The biasing force applied by the spring mechanism 73 presses
the first frame 71 from above against the first substrate 81 and
the second frame 72 from below against the second substrate 82.
[0042] The tubular section 75 has an evacuation space 752 formed in
its interior. An opening 754 communicated with the evacuation space
752 is formed in a lower surface of the tubular section 75 (in
other words, a surface of the tubular section 75 which faces the
first substrate 81).
[0043] As schematically illustrated in FIG. 8, the tubular section
75 of the sealing head 7 is connected to a vacuum pump 3 through an
exhaust passage 2. The exhaust device 1 used in the evacuation step
includes the exhaust passage 2 connected to the sealing head 7, the
vacuum pump 3 connected to the exhaust passage 2, a pressure gauge
4 connected to the exhaust passage 2, and a gas introduction path 5
connected to the exhaust passage 2. The exhaust passage 2 is
provided with an on-off valve 25, and the gas introduction path 5
is provided with an on-off valve 55.
[0044] The sealing head 7 is attached to the work in progress 8,
and the exhaust device 1 is driven (i.e., the vacuum pump 3 is
driven), thereby exhausting air from the internal space 85 through
the evacuation port 815 of the work in progress 8, the sealing head
7, and the exhaust passage 2. A state where the sealing head 7 is
attached to the work in progress 8 is, in other words, a state
where the sealing head 7 is attached to the first substrate 81.
[0045] In the evacuation space 752 of the sealing head 7, a
pressing member 76 is disposed. The pressing member 76 integrally
includes a base 761 having a plate-like shape and a pushing pin 765
having a columnar shape and protruding downward from part of the
base 761. In the evacuation space 752, the pressing member 76 is
movable upward/downward (i.e., toward/away from the second
substrate 82).
[0046] In the evacuation space 752, a spring member 74 configured
to apply biasing force to the pressing member 76 is further
disposed. The spring member 74 is pressed against the base 761 of
the pressing member 76, thereby applying biasing force downward to
the pressing member 76. The biasing force applied by the spring
member 74 to the pressing member 76 is biasing force that pushes
out the pushing pin 765 downward (i.e., in a direction toward the
second substrate 82) through the opening 754.
[0047] The lower surface of the tubular section 75 has a portion
surrounding the opening 754 and provided with an O-ring 77 which is
elastic.
[0048] The heater 79 supported by the second frame 72 is an
infrared radiator configured to emit infrared rays for local
heating. The heater 79 is configured to externally irradiate the
sealing material 89, which is inserted in the evacuation port 815
and which is heat fusible, with infrared rays through the second
substrate 82 which is light transmissive (i.e., through the second
glass panel 820), thereby locally heating the sealing material
89.
[0049] The heater 79 includes a heat source 791 configured to emit
infrared rays and a focusing member 792 configured to focus the
infrared rays emitted from the heat source 791 on a target site.
The heat source 791 is preferably, but not limited to, a halogen
lamp configured to emit near infrared rays.
[0050] With the sealing head 7 having the structure described
above, the evacuation step is performed in the following way.
[0051] To perform the evacuation step, the work in progress 8 is
set such that the first substrate 81 keeps its position located
above the second substrate 82. In a state where the work in
progress 8 is set, the evacuation port 815 is open upward.
[0052] As illustrated in FIG. 5, in a state where the sealing head
7 is attached to the corner portion 8a of the work in progress 8, a
tip end of the pushing pin 765 protruding downward through the
opening 754 of the tubular section 75 is pressed by the biasing
force applied from the spring member 74 against an upper surface of
the plate 88. The sealing material 89 and the plate 88 are
vertically sandwiched between the second substrate 82 and the
pressing member 76 by the biasing force applied from the spring
member 74.
[0053] This brings the O-ring 77 of the sealing head 7 into
airtight contact with the area, surrounding the evacuation port 815
entirely, of an upper surface of the first substrate 81.
[0054] In this state, opening the on-off valve 25 of the exhaust
device 1 shown in FIG. 8 to drive the vacuum pump 3 discharges air
from the evacuation space 752 of the sealing head 7 (see the hollow
arrow in FIG. 5), and the internal space 85 of the work in progress
8 is evacuated to, for example, the degree of vacuum of 0.1 Pa or
lower.
[0055] Next, the sealing step will be described. In the sealing
step, the heater 79 supported by the second frame 72 is used to
seal the evacuation port 815 while the evacuated state in the
internal space 85 is maintained.
[0056] When the evacuated state in the internal space 85 is
maintained, the heater 79 locally heats, in a non-contact manner,
the sealing material 89 inserted in the evacuation port 815 (see
FIG. 6).
[0057] The sealing material 89 locally heated starts softening when
a prescribed softening point is reached. The sealing material 89
thus softened is pushed toward the second substrate 82 by the
biasing force applied by the spring member 74 via the pressing
member 76 and the plate 88 to the sealing material 89 and is
deformed in the internal space 85. At that time, the sealing
material 89 is pressed to spread in a direction orthogonal to a
direction in which the first substrate 81 and the second substrate
82 face each other.
[0058] In the sealing step, when the sealing material 89 thus
softened (in other words, the sealing material 89 with increased
flowability) blocks ventilation between the evacuation port 815 and
the internal space 85, vacuuming of the exhaust device 1 is stopped
(i.e., the vacuum pump 3 is stopped) and the on-off valve 55 of the
gas introduction path 5 is opened. This introduces air through the
gas introduction path 5 into the exhaust passage 2. The air
introduced into the exhaust passage 2 is supplied through the
exhaust passage 2 and the evacuation space 752, communicated
therewith, of the tubular section 75 toward the evacuation port 815
(see the hollow arrow in FIG. 7).
[0059] The pressure of the air supplied here acts to further push
the sealing material 89 thus softened toward the second substrate
82. Thus, the sealing material 89 is pressed to spread in a
balanced manner. That is, in the sealing step of the manufacturing
method of the one embodiment, the sealing material 89 is pressed to
spread at first by the pressure of the pushing pin 765, and
subsequently, the sealing material 89 is pressed to spread in a
balanced manner by the pressure of the air in addition to the
pressure of the pushing pin 765.
[0060] Moreover, microbubbles may be formed in the interior of the
sealing material 89 when the sealing material 89 is softened
(melted), but those microbubbles are burst by applying the pressure
of the air to the sealing material 89 thus softened.
[0061] The air supplied through the gas introduction path 5 is
preferably heated dry air. The temperature of the air to be
supplied is preferably a temperature within the range of a general
room temperature to 300.degree. C. In the sealing step of the
manufacturing method of the one embodiment, the temperature of the
air to be supplied through the gas introduction path 5 is, for
example, a temperature within the range of 100.degree. C. to
300.degree. C., more preferably a temperature within the range of
200.degree. C. to 300.degree. C.
[0062] The closer the temperature of the air to be supplied through
the gas introduction path 5 is to the temperature of the sealing
material 89, the more the sealing of the evacuation port 815 is
suppressed from being influenced by damage or the like caused by a
rapid change in the temperature of the sealing material 89. The air
to be supplied through the gas introduction path 5 is, with
reference to the softening point of the sealing material 89,
preferably a temperature within the range of +/-100.degree. C. from
the softening point, more preferably a temperature within the range
of +/-50.degree. C. from the softening point.
[0063] In the manufacturing method of the one embodiment, heating
of the sealing material 89 is stopped when the air is supplied to
the exhaust passage 2, but the air may be introduced while the
heating of the sealing material 89 is continued.
[0064] Moreover, in the insertion step of the manufacturing method
of the one embodiment, the plate 88 is inserted into the evacuation
port 815, but the plate 88 is not essential. The tip end of the
pushing pin 765 may be directly pressed against the sealing
material 89 without inserting the plate 88 into the evacuation port
815. In this case, if the location of the pushing pin 765 is
shifted, pressing the sealing material 89 to spread in a balanced
manner becomes difficult, but eventually, the pressure of the air
enables the sealing material 89 to be pressed to spread in a
balanced manner.
[0065] Moreover, in the manufacturing method of the one embodiment,
the dam 87 for restricting the deformation range of the sealing
material 89 is disposed in the internal space 85, but the dam 87 is
not essential. Without providing the dam 87 in the internal space
85, the sealing material 89 may be deformed in the internal space
85, and the sealing material 89 after the deformation may seal the
evacuation port 815.
[0066] The manufacturing method of the one embodiment has been
described above. According to the manufacturing method, simple
processes performed with the exhaust device 1 and the sealing head
7 evacuate the internal space 85 of the work in progress 8, and the
evacuation port 815 used for the evacuation can be highly reliably
sealed with the sealing material 89. The glass panel unit 9 thus
manufactured has no trace of the exhaust pipe, which is, however;
left in a conventional technique.
[0067] Next, various types of variations of the manufacturing
method of the one embodiment will be described. In the description
of the variations, components similar to those described above will
be designated by the same reference signs as those in the above
description, and the detailed description thereof will be omitted
herein. Components different from those described above will be
described below.
[0068] (First Variation)
[0069] FIG. 10 schematically shows an exhaust device 1 used in a
first variation of the manufacturing method of the one embodiment.
The exhaust device 1 used in the first variation further includes:
a compressor 6 connected to an exhaust passage 2 via a gas
introduction path 5; and a regulator 57 for pressure adjustment
provided in a flow path of the gas introduction path 5.
[0070] That is, in the exhaust device 1 used in the first
variation, the gas introduction path 5 is disposed between the
compressor 6 for supplying compressed air and the exhaust passage
2, and an on-off valve 55 and the regulator 57 are disposed in the
flow path of the gas introduction path 5.
[0071] In a sealing step of the first variation, when a sealing
material 89 softened by being heated blocks ventilation between an
evacuation port 815 and an internal space 85, vacuuming of the
exhaust device 1 is stopped a vacuum pump 3 is stopped), the on-off
valve 55 in the gas introduction path 5 is opened, and the
compressor 6 is driven. The compressed air sent from the compressor
6 to the gas introduction path 5 is subjected to pressure
adjustment via the regulator 57, is then supplied to the exhaust
passage 2, and is supplied through an evacuation space 752 of the
sealing head 7 toward the evacuation port 815.
[0072] The temperature of the compressed air to be supplied from
the compressor 6 is preferably higher than a general room
temperature and is preferably lower than or equal to 300.degree. C.
The temperature of the compressed air to be supplied from the
compressor 6 is, for example, a temperature within the range of
100.degree. C. to 300.degree. C., more preferably a temperature
within the range of 200.degree. C. to 300.degree. C. The closer the
temperature of the compressed air to be supplied from the
compressor 6 is to the temperature of the sealing material 89, the
more the sealing of the evacuation port 815 is suppressed from
being influenced by damage or the like caused by a rapid change in
the temperature of the sealing material 89. The temperature of the
compressed air to be supplied is, with reference to the softening
point of the sealing material 89, preferably a temperature within
the range of +/-100.degree. C. from the softening point, more
preferably a temperature within the range of +/-50.degree. C. from
the softening point.
[0073] Heating of the sealing material 89 is stopped when the
compressed air is supplied from the compressor 6 to the exhaust
passage 2, but the compressed air may be supplied while the heating
of the sealing material 89 is continued.
[0074] A tip end of the pushing pin 765 may be directly pressed
against the sealing material 89 without inserting the plate 88 into
the evacuation port 815. In this case, if the location of the
pushing pin 765 is shifted, pressing the sealing material 89 to
spread in a balanced manner becomes difficult, but eventually, the
pressure of the compressed air enables the sealing material 89 to
be pressed to spread in a balanced manner.
[0075] (Second Variation)
[0076] FIG. 11 schematically shows an exhaust device 1 used in a
second variation. The second variation includes a plurality of
sealing heads 7. The exhaust device 1 used in the second variation
includes the exhaust passage 2 connected to the plurality of
sealing heads 7, the vacuum pump 3 connected to the exhaust passage
2, a pressure gauge 4 connected to the exhaust passage 2, and a gas
introduction path 5 connected to the exhaust passage 2.
[0077] The exhaust passage 2 includes a manifold 21 and a plurality
of pipelines 23 connected to the plurality of sealing heads 7 on a
one-to-one basis. Each of the plurality of pipelines 23 is
connected to the manifold 21. The plurality of pipelines 23 are
provided with respective on-off valves 25. The vacuum pump 3, the
pressure gauge 4, and the gas introduction path 5 are connected to
the manifold 21.
[0078] In an evacuation step of the second variation, the plurality
of sealing heads 7 are attached to a plurality of works in progress
8 on a one-to-one basis, and in this state, the vacuum pump 3 is
driven, and thereby, the exhaust device 1 is vacuumed and internal
spaces 85 of the plurality of works in progress 8 are
simultaneously evacuated.
[0079] In a sealing step of the second variation, respective
sealing materials 89 of the plurality of works in progress 8 are
heated, and in a state where the internal spaces 85 are closed with
the sealing materials 89 thus softened, vacuuming of the exhaust
device 1 is stopped (i.e., the vacuum pump 3 is stopped), and an
on-off valve 55 is opened to introduce air into the exhaust passage
2. The air introduced into the exhaust passage 2 is supplied
through the plurality of pipelines 23 and the plurality of sealing
heads 7 toward evacuation ports 815 of the plurality of works in
progress 8.
[0080] The second variation enables the plurality of works in
progress 8 to be collectively subjected to the evacuation step and
the sealing step to concurrently manufacture a plurality of glass
panel units 9.
[0081] (Third Variation)
[0082] FIG. 12 schematically shows an exhaust device 1 used in a
third variation. The exhaust device 1 used in the third variation
has a configuration corresponding to a combination of the first
variation and the second variation.
[0083] That is, the third variation includes a plurality of sealing
heads 7 in a similar manner to the second variation. The exhaust
device 1 in the third variation includes the exhaust passage 2
connected to the plurality of sealing heads 7, the vacuum pump 3
connected to the exhaust passage 2, a pressure gauge 4 connected to
the exhaust passage 2, and a gas introduction path 5 connected to
the exhaust passage 2. The exhaust device 1 used in the third
variation further includes a compressor 6 connected to the gas
introduction path 5 and a regulator 57 for pressure adjustment
provided in a flow path of the gas introduction path 5.
[0084] The exhaust passage 2 includes a manifold 21 and a plurality
of pipelines 23 connected to the plurality of sealing heads 7 on a
one-to-one basis. Each of the plurality of pipelines 23 is
connected to the manifold 21. The plurality of pipelines 23 are
provided with respective on-off valves 25. The vacuum pump 3, the
pressure gauge 4, and the gas introduction path 5 are connected to
the manifold 21.
[0085] In an evacuation step of the third variation, the plurality
of sealing heads 7 are attached to a plurality of works in progress
8 on a one-to-one basis, and in this state, the vacuum pump 3 is
driven, and thereby, internal spaces 85 of the plurality of works
in progress 8 are simultaneously evacuated.
[0086] In a sealing step of the third variation, respective sealing
materials 89 of the plurality of works in progress 8 are heated,
and in a state where the internal spaces 85 are closed with the
sealing materials 89 thus softened, the vacuum pump 3 of the
exhaust device 1 is stopped, an on-off valve 55 of the gas
introduction path 5 is opened, and the compressor 6 is driven. The
compressed air sent from the compressor 6 to the gas introduction
path 5 is subjected to pressure adjustment via the regulator 57, is
then supplied to the exhaust passage 2, and is supplied through the
plurality of pipelines 23 and the plurality of sealing heads 7
toward evacuation ports 815 of the plurality of works in progress
8.
[0087] The third variation enables the plurality of works in
progress 8 to be collectively subjected to the evacuation step and
the sealing step to concurrently manufacture a plurality of glass
panel units 9.
[0088] (Aspects)
[0089] As can be seen from the one embodiment and various types of
variations of the one embodiment, a glass panel unit manufacturing
method of a first aspect includes a bonding step, an insertion
step, an evacuation step, and a sealing step. The bonding step
includes bonding a first substrate (81) and a second substrate (82)
together with a bonding material (83) provided between the first
substrate (81) and the second substrate (82) and having a frame
shape. The first substrate (81) includes a glass panel (810) and
has an evacuation port (815). The second substrate (82) includes a
glass panel (820), Thus, an internal space (85) surrounded by the
bonding material (83) is formed between the first substrate (81)
and the second substrate (82). The insertion step includes
inserting a sealing material (89) into the evacuation port (815) of
the first substrate (81). The evacuation step includes evacuating
the internal space (85) through an exhaust passage (2) by
detachably connecting the exhaust passage (2) to the evacuation
port (815). The sealing step includes: deforming the sealing
material by heating; and sealing the evacuation port (815) with the
sealing material (89) deformed by being heated while an evacuated
state in the internal space (85) is maintained. The sealing step
includes supplying gas through the exhaust passage (2) toward the
evacuation port (815) in a state where the sealing material (89)
softened by being heated blocks ventilation between the evacuation
port (815) and the internal space (85).
[0090] According to the glass panel unit manufacturing method of
the first aspect, the gas supplied in the sealing step applies, to
the sealing material (89), pressure that pushes the sealing
material (89) toward the second substrate (82). Thus, the sealing
material (89) is pressed to spread in a balanced manner. In
addition, microbubbles formed while the sealing material 89 is
softened can be burst by the pressure of the gas. Thus, according
to the glass panel unit manufacturing method of the first aspect,
the evacuation port (815) fused for evacuation of the internal
space (85) is be highly reliably sealed with the sealing material
(89) while the evacuated state in the internal space (85) is
maintained. The glass panel unit (9) manufactured has no trace of
the exhaust pipe, which is, however, left in a conventional
technique.
[0091] A glass panel unit manufacturing method of a second aspect
is realized in combination with the first aspect. In the glass
panel unit manufacturing method of the second aspect, the gas
supplied through the exhaust passage (2) toward the evacuation port
(815) is heated external air.
[0092] The glass panel unit manufacturing method of the second
aspect suppresses damage or the like from being caused by a rapid
temperature drop in part of the work in progress (8) of the glass
panel unit (9) due to the influence of the gas supplied.
[0093] A glass panel unit manufacturing method of a third aspect is
realized in combination with the first aspect. In the glass panel
unit manufacturing method of the third aspect, the gas supplied
through the exhaust passage (2) toward the evacuation port (815) is
compressed air.
[0094] The glass panel unit manufacturing method of the third
aspect enables the sealing material (89) to be pressed to spread in
a balanced manner by the compressed air. In addition, microbubbles
formed while the sealing material 89 is softened can be burst by
the pressure of the compressed air.
[0095] A glass panel unit manufacturing method of a fourth aspect
is realized in combination with any one of the first to third
aspects. In the glass panel unit manufacturing method of the fourth
aspect, the gas has a temperature in a range of 100.degree. C. to
300.degree. C.
[0096] The glass panel unit manufacturing method of the fourth
aspect suppresses damage or the like from being caused by a rapid
temperature change in part of the work in progress (8) of the glass
panel unit (9) due to the influence of the gas supplied.
[0097] A glass panel unit manufacturing method of a fifth aspect is
realized in combination with any one of the first to third aspects.
In the glass panel unit manufacturing method of the fifth aspect,
the gas has a temperature in a range of 200.degree. C. to
300.degree. C.
[0098] The glass panel unit manufacturing method of the fifth
aspect suppresses damage or the like from being caused by a rapid
temperature change in part of the work in progress (8) of the glass
panel unit (9) due to the influence of the gas supplied.
[0099] A glass panel unit manufacturing method of a sixth aspect is
realized in combination with any one of the first to third aspects.
In the g glass panel unit manufacturing method of the sixth aspect,
the gas has a temperature in a range of +/-100.degree. C. from a
softening point of the sealing material (89).
[0100] The glass panel unit manufacturing method of the sixth
aspect suppresses sealing of the evacuation port (815) from being
influenced by damage or the like due to a rapid change in the
temperature of the sealing material (89).
[0101] A glass panel unit manufacturing method of a seventh aspect
is realized in combination with any one of the first to third
aspects. In the glass panel unit manufacturing method of the
seventh aspect, the gas has a temperature in a range of
+/-50.degree. C. from a softening point of the sealing material
(89).
[0102] The glass panel unit manufacturing method of the seventh
aspect suppresses sealing of the evacuation port (815) from being
influenced by damage or the like due to a rapid change in the
temperature of the sealing material (89).
[0103] A glass panel unit manufacturing method of an eighth aspect
is realized in combination with any one of the first to seventh
aspects. In the glass panel unit manufacturing method of the eighth
aspect, the evacuation step and the sealing step are performed with
an exhaust device (1) having the exhaust passage (2) and a sealing
head (7) connected to the exhaust passage (2) in a state where the
sealing head (7) is attached to the first substrate (81). The
sealing step includes supplying gas through the exhaust passage (2)
and the sealing head (7) toward the evacuation port (815).
[0104] Thus, according to the glass panel unit manufacturing method
of the eighth aspect, the evacuation port (815) fused for
evacuation of the internal space (85) is be highly reliably sealed
with the sealing material (89) by simple processes with the exhaust
device (1) and the sealing head (7) while the evacuated state in
the internal space (85) is maintained.
[0105] A glass panel unit manufacturing method of a ninth aspect is
realized in combination with the eighth aspect. In the glass panel
unit manufacturing method of the ninth aspect, in the evacuation
step and the sealing step, a plurality of the sealing heads (7) are
used.
[0106] The glass panel unit manufacturing method of the ninth
aspect enables a plurality of glass panel units (9) to be
concurrently manufactured with the plurality of sealing heads
(7).
[0107] A glass panel unit manufacturing method of a tenth aspect is
realized in combination with the third aspect. In the glass panel
unit manufacturing method of the tenth aspect, the evacuation step
and the sealing step are per with an exhaust device (1) having the
exhaust passage (2) and a compressor (6) connected to the exhaust
passage (2) and a sealing head (7) connected to the exhaust passage
(2) in a state where the sealing head (7) is attached to the first
substrate (81). The sealing step includes supplying compressed gas
from the compressor (6) through the exhaust passage (2) and the
sealing head (7) toward the evacuation port (815).
[0108] Thus, according to the glass panel unit manufacturing method
of the tenth aspect, the evacuation port (815) fused for evacuation
of the internal space (85) is be highly reliably sealed with the
sealing material (89) by simple processes with the exhaust device
(1) and the sealing head (7) while the evacuated state in the
internal space (85) is maintained.
[0109] A glass panel unit manufacturing method of an eleventh
aspect is realized in combination with the tenth aspect. In the
glass panel unit manufacturing method of the eleventh aspect, in
the evacuation step and the sealing step, a plurality of the
sealing heads (7) are used.
[0110] The glass panel unit manufacturing method of the eleventh
aspect enables a plurality of glass panel units (9) to be
concurrently manufactured with the plurality of sealing heads
(7).
[0111] A glass panel unit manufacturing method of the twelfth
aspect is realized in combination with any one of the first to
eleventh aspects. In the glass panel unit manufacturing method of
the twelfth aspect, in the sealing step, the sealing material (89)
softened by being heated is deformed by being pressed by the
pressing member (76) inserted into the evacuation port (815). The
sealing material (89) deformed by being pressed blocks ventilation
between the evacuation port (815) and the internal space (85).
[0112] In the glass panel unit manufacturing method of a twelfth
aspect, the sealing material (89) is first pressed to spread by the
pressing member (76), the pressure of the gas is then further
applied to the sealing material (89), and thereby, the sealing
material (89) is pressed to spread in a balanced manner.
[0113] A glass panel unit manufacturing method of the thirteenth
aspect is realized in combination with any one of the first to
twelfth aspects. In the glass panel unit manufacturing method of
the thirteenth aspect, the sealing step includes irradiating the
sealing material (89) with infrared rays through the second
substrate (82) to locally heat the sealing material (89).
[0114] The glass panel unit manufacturing method of the thirteenth
aspect enables the sealing material (89) to be efficiently locally
heated while the evacuated state in the internal space (85) is
maintained.
REFERENCE SIGNS LIST
[0115] 2 EXHAUST PASSAGE [0116] 76 PRESSING MEMBER [0117] 81 FIRST
SUBSTRATE [0118] 810 GLASS PANEL [0119] 815 EVACUATION PORT [0120]
82 SECOND SUBSTRATE [0121] 820 GLASS PANEL [0122] 83 BONDING
MATERIAL [0123] 85 INTERNAL SPACE [0124] 89 SEALING MATERIAL [0125]
9 GLASS PANEL UNIT
* * * * *